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Barrel vs Rack Plating: Which Is Right for Your Components?

At EC Williams, we are often asked to explain the difference between barrel and rack plating. Both methods are widely used in electroplating but suit very different applications. If you’re unsure which method fits your components, this guide is for you.

Introduction from EC Williams

We specialise in small parts electroplating for sectors including automotive, electronics, aerospace and defence. The right plating method will impact your cost, lead time, and component quality. This blog will help you choose between barrel plating vs rack plating for small parts, based on real-world experience.

 

Why Plating Method Matters

Electroplating is never one-size-fits-all. The method must match:

  • Component size
  • Part complexity
  • Surface finish requirements
  • Material compatibility

Choosing the right method improves adhesion, reduces handling time and cuts rework.

 

What Is Barrel Plating?

Barrel plating is a high-volume electroplating method. Small parts are loaded into a rotating barrel that turns slowly during the plating cycle.
Advantages:

  • Efficient for bulk processing
  • Low labour cost per part
  • Uniform coating on simple geometries

Best For:

  • Screws, bolts, washers
  • Simple-shaped fasteners
  • Small conductive components

Barrel plating is ideal when cost efficiency is the top priority.

 

What Is Rack Plating?

Rack plating involves mounting parts onto racks or fixtures before immersion. This keeps them stationary and spaced during the process.

Advantages:

  • High-quality surface finish
  • Suitable for delicate or complex shapes
  • Allows selective plating on specific areas

Best For:

  • Connectors and terminals
  • Decorative items
  • Components prone to tangling or damage

If your components are fragile or visually exposed, rack plating ensures care and precision.

When to Use Barrel Plating

Choose barrel plating when:

  • Parts are robust
  • You’re working with high volumes
  • Cost control is essential

Bulk plating cost efficiency makes this method attractive to OEMs and fastener suppliers.

When to Use Rack Plating

Opt for rack plating when:

  • Parts are delicate or irregular
  • Surface quality is critical
  • Contact marks must be avoided

Our rack plating for delicate items uses tailored jigs to protect fragile components and guarantee finish consistency.

 

FAQs

Q1: Does barrel plating damage parts?
No, but some surface wear may occur on fragile or soft metals. That’s why we don’t recommend it for cosmetic parts.

Q2: Can I rack-plate small components?
Yes, especially if the item is precision-machined or cosmetically visible.

Q3: Which method is faster?
Barrel plating is generally quicker for high volumes. Rack plating requires more handling time.

 

How We Do It at EC Williams

We have developed barrel plating techniques which for some components enable us to process them in a barrel rather than have the costly rack plating method..

Considerations for Your Plating Project

1. Component Geometry
Small, solid parts with no sharp edges or deep recesses are ideal for barrel plating.

2. Volume & Budget
Large batches? Choose a barrel. Need cosmetic perfection? Go rack.

3. Plating Finishes

  • Zinc
  • Nickel
  • Tin
  • Zinc-nickel alloys
  • Copper

Our team will advise based on adhesion, thickness, and regulatory requirements.

 

Final Thoughts from EC Williams

Both methods are valuable. The right choice depends on your goals. EC Williams will:

  • Review your technical drawings
  • Recommend the best plating method
  • Deliver to spec, on time

Whether you’re new to plating or upgrading an existing process, we’re here to help.

Contact EC Williams
Phone: 0121 236 2524
Email: plating@ecwilliams.co.uk